Electric drive fault simulation device and electric drive fault simulation method

Abstract

The invention discloses an electric drive fault simulation device and method, and relates to the technical field of electric drive fault equipment and control, and the method comprises the steps that a motor controller detects the fault type of an electric drive system in real time and judges the fault level; the motor controller judges whether the detected fault is only a first-level fault or not; the motor controller judges whether the rotating speed of the motor is smaller than a set value; the motor controller attempts to be powered on for operation every time t1 and detects whether the first-level fault occurs again, and the accumulated occurrence frequency of the first-level fault within the time t2 is counted; and the motor controller performs zero clearing on the built-in fault recovery counter, and the electric drive system is kept electrified to operate. By isolating the high-voltage and low-voltage fault simulation circuits and fixing the high-voltage control circuit, the high-voltage contact risk in operation is reduced. The fault simulation simplifies the simulation process through the touch display operation, and improves the test efficiency. In addition, fault grading and self-recovery strategies are introduced, the automobile is allowed to continuously and stably run under certain fault conditions, and the running safety of the automobile and the experience of passengers are improved.

Description

Technical Field

[0001] The present invention relates to the field of electric drive fault equipment and control technology, and in particular to an electric drive fault simulation device and an electric drive fault simulation method. Background Art

[0002] As the most important power execution unit of electric vehicles, the electric drive system is very important for the safety and comfort of vehicle driving. Therefore, during the development stage of electric vehicles, it is necessary to conduct a thorough test of the potential failures of the electric drive system and propose solutions to ensure its normal operation after it is put on the market.

[0003] At present, the fault testing methods for electric drive systems of electric vehicles include road fault simulation testing and bench fault simulation testing. Among them, in bench fault simulation testing, there is no mature and reliable electric drive fault simulation device on the market, and basically it depends on the electric drive test engineers to manually build simple tooling to conduct testing. This leads to many disadvantages, mainly including the following:

[0004] There is a high risk of high-voltage electric shock: The voltage of electric vehicles is as high as several hundred volts. The high-voltage isolation performance of the manually constructed tooling is poor, and there are no standard operating specifications. When connecting the high-voltage sampling line, workers are very likely to be at risk of high-voltage electric shock, which endangers their lives.

[0005] High-voltage wiring harness sampling is difficult. Since the high-voltage lines of electric vehicles require a protection level of IP67 or above, the conductors of the high-voltage lines are tightly wrapped, and it is very difficult to touch the high-voltage conductors and collect signals with simple tools;

[0006] The sampling signal is unstable. The manually constructed tooling mainly uses simple jumpers, alligator clips, wire breakers and other tools to connect the wiring harness. The connection reliability is poor, and the lines are complicated and easy to connect incorrectly, and there is a risk of short circuits.

[0007] Low work efficiency. There are many types of failures in the electric drive system, and manual tooling requires constant disassembly and assembly of tools, which consumes a lot of manpower and time. Summary of the invention

[0008] In view of the above-mentioned problems, the present invention is proposed.

[0009] Therefore, the technical problem solved by the present invention is that the electric drive system may encounter various types of faults during operation. In the traditional manual tooling method, during the fault simulation and detection process, the operator needs to frequently disassemble and assemble the tools, which not only consumes a lot of human resources, but also significantly prolongs the detection time.

[0010] In order to solve the above technical problems, the present invention provides the following technical solutions: an electric drive fault simulation device, which comprises the following steps:

[0011] High voltage connecting wire, low voltage connecting wire, fault simulation circuit.

[0012] The electric drive fault simulation device is connected to the low-voltage interface of the motor controller through a low-voltage connecting line, and is connected to the three-phase high-voltage interface of the motor controller through a high-voltage connecting line.

[0013] The electric drive fault simulation device is connected to the low-voltage interface of the drive motor through a low-voltage connecting line, and is connected to the three-phase high-voltage interface of the drive motor through a high-voltage connecting line.

[0014] The electric drive fault simulation device comprises a plurality of fault simulation circuits, and two ends of each fault simulation circuit are respectively connected to a motor controller and a drive motor.

[0015] The fault simulation circuit includes a communication fault simulation circuit, a high-voltage interlock fault simulation circuit, an over-temperature fault simulation circuit, a resolver signal loss fault simulation circuit, a resolver signal abnormality fault simulation circuit, a phase current abnormality / hardware over-current fault simulation circuit and an insulation failure fault simulation circuit.

[0016] Each fault simulation circuit is respectively provided with a relay for controlling the on and off of the fault simulation circuit.

[0017] As a preferred solution of the electric drive fault simulation device described in the present invention, the communication fault simulation circuit includes a first relay, a first connecting line, a second connecting line and a first resistor, one end of the first connecting line and the second connecting line are connected in series through the first relay and the first resistor, and the other end of the first connecting line and the second connecting line are respectively connected to CANH and CANL of the vehicle CAN network through low-voltage cables.

[0018] As a preferred solution of the electric drive fault simulation device described in the present invention, the high-voltage interlock fault simulation circuit includes a second relay, a third connecting line, a fourth connecting line, the two ends of the third connecting line are respectively connected to the low-voltage interface of the motor controller and the low-voltage interface of the motor, the two ends of the fourth connecting line are respectively connected to the low-voltage interface of the motor controller and the low-voltage interface of the motor, and the second relay is arranged on the third connecting line or the fourth connecting line.

[0019] As a preferred solution of an electric drive fault simulation device described in the present invention, wherein: the over-temperature fault simulation circuit includes a third relay, a fifth connecting line, a sixth connecting line and a second resistor, the two ends of the fifth connecting line are respectively connected to the low-voltage interface of the motor controller and the low-voltage interface of the motor, the two ends of the sixth connecting line are respectively connected to the low-voltage interface of the motor controller and the low-voltage interface of the motor, and the third relay and the second resistor are arranged in series between the fifth connecting line and the sixth connecting line.

[0020] As a preferred embodiment of the electric drive fault simulation device described in the present invention, the resolver signal loss / abnormal fault simulation circuit (400) comprises a fourth relay, a fifth relay, a third resistor, a first excitation connection line, a second excitation connection line, a first sine connection line, a second sine connection line, a first cosine connection line and a second cosine connection line, wherein two ends of the first excitation connection line, the second excitation connection line, the first sine connection line, the second sine connection line, the first cosine connection line and the second cosine connection line are respectively connected to the low voltage interface of the motor controller and the low voltage interface of the motor, the fourth relay is arranged on any one of the first sine connection line, the second sine connection line, the first cosine connection line and the second cosine connection line, and the fifth relay is connected in series with the third resistor and then arranged in parallel with the fourth relay on any one of the first sine connection line, the second sine connection line, the first cosine connection line and the second cosine connection line.

[0021] As a preferred solution of an electric drive fault simulation device described in the present invention, the phase current abnormality / hardware overcurrent fault simulation circuit (500) includes a sixth relay, a first high-voltage phase line, a second high-voltage phase line, a third high-voltage phase line and a fourth resistor, the two ends of the first high-voltage phase line are respectively connected to the high-voltage interface of the motor controller and the high-voltage interface of the motor, the two ends of the second high-voltage phase line are respectively connected to the high-voltage interface of the motor controller and the high-voltage interface of the motor, the two ends of the third high-voltage phase line are respectively connected to the high-voltage interface of the motor controller and the high-voltage interface of the motor, and the sixth relay and the fourth resistor are connected in series and connected between any two high-voltage phase lines.

[0022] As a preferred embodiment of the electric drive fault simulation device described in the present invention, the insulation failure fault simulation circuit includes a seventh relay, a fifth resistor, a fourth high-voltage phase line, a fifth high-voltage phase line, a sixth high-voltage phase line and a vehicle body ground, the two ends of the fourth high-voltage phase line are respectively connected to the high-voltage interface of the motor controller and the high-voltage interface of the motor, the two ends of the fifth high-voltage phase line are respectively connected to the high-voltage interface of the motor controller and the high-voltage interface of the motor, the two ends of the sixth high-voltage phase line are respectively connected to the high-voltage interface of the motor controller and the high-voltage interface of the motor, and the seventh relay and the fifth resistor are arranged in series between any one of the high-voltage phase lines and the vehicle body ground.

[0023] Another object of the present invention is to provide an electric drive fault simulation method, which can accurately simulate various fault situations that may occur in the electric drive system through advanced simulation software and hardware integration system, thereby solving the problems of inaccurate diagnosis and delayed response caused by lack of actual fault data and inaccurate fault simulation in the prior art.

[0024] To solve the above technical problems, the present invention provides the following technical solutions: an electric drive fault simulation method, comprising: selecting different fault simulation modes; the fault simulation modes include single fault simulation modes and multiple fault simulation modes; based on different fault simulation modes, taking different control measures for the relays of each fault simulation circuit.

[0025] As a preferred solution of the electric drive fault simulation method of the present invention, wherein: based on different fault simulation modes, taking different control measures for the relays of each fault simulation circuit includes, in the single fault simulation mode:

[0026] A fault type to be simulated is determined, and a relay of a fault simulation circuit corresponding to the fault type is controlled to close.

[0027] When another fault type that needs to be simulated is determined, the relay of the fault simulation circuit that is currently turned on is controlled to be disconnected, and then the relay of the fault simulation circuit corresponding to the other fault type that needs to be simulated is controlled to be closed.

[0028] As a preferred scheme of the electric drive fault simulation method described in the present invention, wherein: based on different fault simulation modes, different control measures are taken for the relays of the fault simulation circuits, including: in the multi-fault simulation mode: determining multiple fault types that need to be simulated, and controlling the closure of the relays of the fault simulation circuits corresponding to the multiple fault types.

[0029] Beneficial effects of the present invention: The electric drive fault simulation device of the present invention can simulate multiple common electric drive system fault types such as communication fault, high-voltage interlock fault, over-temperature fault, loss of resolver signal, abnormal resolver signal, abnormal phase current, hardware overcurrent and insulation failure. The device realizes the fixed connection of the high-voltage fault simulation circuit through the isolation design of the high-voltage and low-voltage fault simulation circuits, avoiding the need to manually connect the high-voltage circuit each time the fault is simulated, thereby significantly reducing the safety risk of high-voltage contact. Each fault simulation circuit is equipped with a relay, and different types of faults are accurately simulated by closing or disconnecting the relay. For example, the communication fault simulation circuit controls the signal interruption of the CAN network through the relay, the high-voltage interlock fault simulation circuit disconnects the low-voltage connection between the motor controller and the motor through the relay, and the over-temperature fault simulation circuit controls the disconnection of the temperature monitoring circuit between the motor controller and the motor through the relay. The device supports single fault simulation mode and multi-fault simulation mode, and can simulate a single fault or multiple fault types occurring simultaneously, respectively, to meet the test requirements of complex fault scenarios. During the simulation process, the device automatically controls the relay, no longer relies on manual wiring, simplifies the operation process, improves the test efficiency, and greatly reduces the safety hazards of manual operation, especially in high-voltage simulation. In addition, the fault simulation method ensures accurate simulation of fault types by precisely controlling the closing and opening of relays, effectively improving the flexibility, safety and reliability of the simulation process, and is widely used in the research and development, testing and fault diagnosis of electric drive systems. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0031] Figure 1 An overall framework diagram of an electric drive fault simulation device provided in the first embodiment of the present invention.

[0032] Figure 2 An overall flow chart of an electric drive fault simulation method provided for the second embodiment of the present invention. DETAILED DESCRIPTION

[0033] In order to make the above-mentioned purposes, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the drawings of the specification. Obviously, the described embodiments are part of the embodiments of the present invention, but not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary persons in the art without creative work should fall within the scope of protection of the present invention.

[0034] Example 1, reference Figure 1 , is an embodiment of the present invention, and provides an electric drive fault simulation device, characterized in that:

[0035] High voltage connectors, high voltage connecting wires, low voltage connectors, low voltage connecting wires, fault simulation circuits, and control host.

[0036] The electric drive fault simulation device is connected to the low-voltage interface of the motor controller through a low-voltage connecting line, and is connected to the U, V, W three-phase high-voltage interface of the motor controller (motor controller) through a high-voltage connecting line.

[0037] The electric drive fault simulation device is connected to the low-voltage interface of the drive motor through a low-voltage connecting line, and is connected to the U, V, W three-phase high-voltage interfaces of the drive motor through a high-voltage connecting line.

[0038] The two ends of each fault simulation circuit inside the electric drive fault simulation device are connected to the corresponding pins of the motor controller and the drive motor (drive motor) respectively.

[0039] The control host is responsible for signal reception, relay control and mode switching.

[0040] Signal reception is to control the output relay by receiving button input signals.

[0041] Relay control is to control the opening and closing of K1-K7 relays to simulate different electric drive system faults.

[0042] The mode switching is divided into single fault simulation and multi-fault simulation according to the button input information through the upper computer programming, and different relay control strategies are adopted in different modes.

[0043] The fault simulation circuit includes a communication fault simulation circuit 100 , a high-voltage interlock fault simulation circuit 200 , an over-temperature fault simulation circuit 300 , a resolver signal loss / abnormal fault simulation circuit 400 , a phase current abnormality / hardware over-current fault simulation circuit 500 , and an insulation failure fault simulation circuit 600 .

[0044] The communication fault simulation circuit 100 includes a first relay, a first connecting line, a second connecting line and a first resistor. One end of the first connecting line and the second connecting line are connected in series through the first relay and the first resistor, and the other end of the first connecting line and the second connecting line are respectively connected to CANH and CANL of the vehicle CAN network through low-voltage cables.

[0045] Specifically, the communication fault simulation circuit 100 is composed of two communication lines CANH and CANL, and a low-voltage relay K7 and a resistor R5 connected therebetween, and the value range of R5 is 0-120Ω.

[0046] The high-voltage interlock fault simulation circuit 200 includes a second relay, a third connecting line, a fourth connecting line, and both ends of the third connecting line are respectively connected to the low-voltage interface of the motor controller and the low-voltage interface of the motor, and both ends of the fourth connecting line are respectively connected to the low-voltage interface of the motor controller and the low-voltage interface of the motor, and the second relay is arranged on the third connecting line or the fourth connecting line.

[0047] The high-voltage interlock fault simulation circuit 200 is composed of two low-voltage lines for high-voltage interlocking and a low-voltage relay K6 connected to any one of the lines.

[0048] The over-temperature fault simulation circuit 300 includes a third relay, a fifth connecting line, a sixth connecting line and a second resistor. The two ends of the fifth connecting line are respectively connected to the low-voltage interface of the motor controller and the low-voltage interface of the motor. The two ends of the sixth connecting line are respectively connected to the low-voltage interface of the motor controller and the low-voltage interface of the motor. The third relay and the second resistor are arranged in series between the fifth connecting line and the sixth connecting line.

[0049] Specifically, the over-temperature fault simulation circuit 300 is composed of two low-voltage lines connected to the NTC temperature sensor and a low-voltage relay K5 and a resistor R4 connected therebetween, and the value range of R4 is 0-2 drive motor Ω.

[0050] The resolver signal loss / abnormal fault simulation circuit 400 includes a fourth relay, a fifth relay, a third resistor, a first excitation low-voltage line, a second excitation low-voltage line, a first sine low-voltage line, a second sine low-voltage line, a first cosine low-voltage line, and a second cosine low-voltage line. The first excitation connecting line, the second excitation connecting line, the first sine connecting line, the second sine connecting line, the first cosine connecting line, and the second cosine connecting line are respectively connected to the low-voltage interface of the motor controller and the low-voltage interface of the motor through low-voltage cables. The fourth relay is arranged on the first sine connecting line, the second sine connecting line, the first cosine connecting line, and the second cosine connecting line. The fifth relay and the third resistor are arranged in parallel with the first relay on the first sine connecting line, the second sine connecting line, the first cosine connecting line, and the second cosine connecting line.

[0051] Among them, the resolver signal loss fault simulation circuit consists of six low-voltage lines, including 2 excitation lines, 2 sine lines, and 2 cosine lines, and a low-voltage relay K3 connected to any one of the sine and cosine lines.

[0052] The resolver signal abnormal fault simulation circuit consists of six low-voltage lines, including 2 excitation lines, 2 sine lines, and 2 cosine lines, and a low-voltage relay K4 and a resistor R3 connected to any one of the sine and cosine lines. The value range of R3 is 50Ω-2 drive motor Ω.

[0053] The phase current abnormality / hardware overcurrent fault simulation circuit 500 includes a sixth relay, a first high-voltage phase line, a second high-voltage phase line, a third high-voltage phase line and a fourth resistor. The two ends of the first high-voltage phase line are respectively connected to the high-voltage interface of the motor controller and the high-voltage interface of the motor, the two ends of the second high-voltage phase line are respectively connected to the high-voltage interface of the motor controller and the high-voltage interface of the motor, and the two ends of the third high-voltage phase line are respectively connected to the high-voltage interface of the motor controller and the high-voltage interface of the motor. After the sixth relay and the fourth resistor are connected in series, they are connected between any two high-voltage phase lines.

[0054] Specifically, the phase current abnormality / hardware overcurrent fault simulation circuit 500 consists of three high-voltage phase lines U, V, and W, and a high-voltage relay K2 and a power resistor R2 connected to any two phase lines. The withstand voltage range of K2 is 200-2000V, the value range of R2 is 0Ω-2 drive motor Ω, and the heat dissipation power is 0-20kW.

[0055] The insulation failure fault simulation circuit 600 includes a seventh relay, a fifth resistor, a fourth high-voltage phase line, a fifth high-voltage phase line, a sixth high-voltage phase line and a vehicle body ground. The two ends of the fourth high-voltage phase line are respectively connected to the high-voltage interface of the motor controller and the high-voltage interface of the motor, the two ends of the fifth high-voltage phase line are respectively connected to the high-voltage interface of the motor controller and the high-voltage interface of the motor, the two ends of the sixth high-voltage phase line are respectively connected to the high-voltage interface of the motor controller and the high-voltage interface of the motor, and the seventh relay and the fifth resistor are arranged in series between any one of the high-voltage phase lines and the vehicle body ground.

[0056] Specifically, the insulation failure fault simulation circuit 600 consists of three high-voltage phase lines U, V, and W, a ground line, and a high-voltage relay K1 and a power resistor R1 connected between any one of the phase lines and the ground line. The withstand voltage range of K1 is 200-2000V, the value range of R1 is 100Ω-2 drive motor Ω, and the heat dissipation power is 0-10kW.

[0057] All the above relays K1-K7 are normally open relays, and their opening and closing are controlled by the control host of the electric drive system fault simulation device.

[0058] The fault simulation operation process of the electric drive system fault simulation device is as follows:

[0059] 1. The working modes of the electric drive system fault simulation device are divided into two categories: 1) single fault simulation, 2) multiple fault simulation;

[0060] 2. For the single fault simulation mode, the device can only simulate one fault type at the same time. When you need to simulate the electric drive system fault, press the button of the corresponding fault and click to confirm. The control host will control the relay of the corresponding fault circuit to close, thus realizing the fault simulation. When you click the second fault simulation type, the control host will control the relay of the previous fault circuit to disconnect, and then control the relay of the second fault simulation circuit to close;

[0061] 3. For the multi-fault simulation mode, the device can simulate multiple fault types at the same time. When this mode has been selected, when you need to simulate multiple faults of the electric drive system at the same time, you only need to select multiple fault types on the button operation console and click the confirmation button. The control host will control the relay of the corresponding fault circuit to close, thereby realizing the simultaneous simulation of multiple faults.

[0062] 4. For the multi-fault simulation mode, only one of the resolver signal loss fault simulation and the resolver signal abnormal fault simulation can be selected at the same time.

[0063] The electric drive system fault simulation device can simulate the fault by clicking the fault type on the display, reducing the labor of disassembling and assembling the tooling manually, and is highly efficient. The present invention classifies the faults of the electric drive system according to the risk level that the fault may cause to the vehicle driving safety and the passenger experience, and combines the probability of its sporadic occurrence, and proposes a strategy and control method for self-recovery of the fault. For faults with a higher probability of sporadic occurrence and a slightly lower risk, the car can also drive stably.

[0064] Example 2, reference Figure 2 , as an embodiment of the present invention, provides an electric drive fault simulation method for an electric drive fault simulation device, characterized in that:

[0065] One of the means to improve automobile safety is to conduct investigation and analysis of potential electric drive failures during the R&D phase. However, no investigation and testing can guarantee that there will be 100% no failures after the car is launched on the market. Once a car fails during driving, how to quickly, scientifically and reasonably handle the failure is the core technical capability of automobile R&D.

[0066] To this end, the present invention proposes a fault self-recovery strategy. According to the risk level that the fault may cause to vehicle driving safety and passenger experience, and combined with its probability of sporadic occurrence, the fault level of the electric drive system is set to level 2. For faults with a high probability of sporadic occurrence and not extremely urgent risks to personal safety, the present invention defines them as recoverable faults. That is, when the automobile controller detects a fault, it will not immediately shut down the power supply, but will use the judgment method set by the present invention to identify whether it is a recoverable fault and whether it meets the recoverable conditions. If the conditions are met, the electric drive system continues to work, thereby giving the car higher stability and personnel comfort.

[0067] As the most important power execution unit of electric vehicles, if the electric drive system fails during driving, the electric drive system will stop working immediately, which will inevitably cause some very serious consequences. For example, when the car is driving at high speed, if the electric drive system is subject to strong electromagnetic interference from the external substation and an occasional abnormal communication failure occurs, the electric drive will immediately stop working when it recognizes the abnormality, which will inevitably cause a huge impact on the passengers and give them a very bad driving experience.

[0068] Based on this, the present invention classifies and grades the fault types of the electric drive system and designs corresponding fault management strategies.

[0069] Fault classification of electric drive system:

[0070] The present invention classifies the fault types of the electric drive system into:

[0071] The resolver signal is lost.

[0072] The resolver signal is abnormal.

[0073] Motor overtemperature fault.

[0074] Communication failure.

[0075] High voltage interlock fault.

[0076] High voltage insulation failure.

[0077] Phase circuit abnormality.

[0078] Hardware overcurrent fault.

[0079] Fault classification of electric drive systems.

[0080] The present invention sets the fault level of the electric drive system to level 2 based on the degree of risk that the fault may cause to vehicle driving safety and passenger experience, and combined with its probability of contingency.

[0081] 1) Level 1: The risk level is relatively light and is set as a recoverable fault. The types of recoverable faults include: resolver signal loss fault, resolver signal abnormal fault, phase circuit abnormal fault, and hardware overcurrent fault. Once a level 1 fault occurs, the electric drive system immediately powers off and stops running, but an observation period is set. If the recoverable conditions are met during the observation period, the electric drive system is powered on every t1 interval to observe whether the fault disappears. If the level 1 fault meets the recoverable conditions during the observation time, the electric drive system continues to be powered on, otherwise the electric drive system is powered off and stops running.

[0082] 2) Level 2: The risk level is relatively high. Once a level 2 fault occurs, the electric drive system will be directly and continuously powered off and stop running.

[0083] The conditions for recovering from level 1 faults are:

[0084] Single fault recovery time t1; the value of t1 is 10-1000ms.

[0085] The number of faults within time t2 is less than i times; the value of t2 is 10-100s, and the value of i is 1-100.

[0086] The motor speed is lower than n; the value of n is 100-10000rpm.

[0087] Electric drive system fault control method Figure 2 As shown:

[0088] S1: The motor controller detects the electric drive system fault type and determines the fault level in real time.

[0089] Fault levels include level 1 faults and level 2 faults.

[0090] When a fault exists, determine whether only a level 1 fault exists.

[0091] S2: The motor controller determines whether the detected fault is only a level 1 fault.

[0092] If the detected fault is judged to be only a level 1 fault and the judgment result is that there is a level 2 fault, the electric drive system is powered off and stops running.

[0093] If only a primary fault exists, the motor controller determines whether the motor speed is less than a set value.

[0094] S3: The motor controller determines whether the motor speed is less than the set value.

[0095] The result of judging whether the motor speed is less than the set value n is less than the set value, and then the cumulative number of occurrences of the level 1 fault within the time t2 is counted.

[0096] If the motor speed is greater than or equal to the set value, the electric drive system will be powered off and stop running.

[0097] S4: The motor controller attempts to power on and detect whether the level 1 fault occurs again after a time period of t1, and counts the cumulative number of level 1 faults that occur within a time period of t2;

[0098] If the cumulative number of level 1 faults within time t2 is less than the set value, the motor controller clears the built-in fault recovery counter and the electric drive system remains powered on; if the cumulative number of level 1 faults is greater than or equal to the set value, the electric drive system is powered off and stops running.

[0099] S5: The motor controller clears the built-in fault recovery counter and the electric drive system remains powered on.

[0100] If the functions are implemented in the form of software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art or the part of the technical solution, can be embodied in the form of a software product. The computer software product is stored in a storage medium, including several instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the method described in each embodiment of the present invention. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), disk or optical disk, etc., which can store program code.

[0101] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as an ordered list of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by an instruction execution system, device or apparatus (such as a computer-based system, a system including a processor, or other system that can fetch instructions from an instruction execution system, device or apparatus and execute instructions), or in conjunction with such instruction execution systems, devices or apparatuses. For the purposes of this specification, "computer-readable medium" can be any device that can contain, store, communicate, propagate or transmit a program for use by an instruction execution system, device or apparatus, or in conjunction with such instruction execution systems, devices or apparatuses.

[0102] More specific examples of computer-readable media (a non-exhaustive list) include the following: an electrical connection with one or more wires (electronic device), a portable computer disk case (magnetic device), a random access memory (RAM), a read-only memory (ROM), an erasable and programmable read-only memory (EPROM or flash memory), an optical fiber device, and a portable compact disk read-only memory (CDROM). In addition, the computer-readable medium may even be a paper or other suitable medium on which the program is printed, since the program may be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, deciphering or, if necessary, processing in another suitable manner, and then stored in a computer memory.

[0103] It should be understood that the various parts of the present invention can be implemented by hardware, software, firmware or a combination thereof. In the above-mentioned embodiments, a plurality of steps or methods can be implemented by software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if implemented by hardware, as in another embodiment, it can be implemented by any one of the following technologies known in the art or their combination: a discrete logic circuit having a logic gate circuit for implementing a logic function for a data signal, a dedicated integrated circuit having a suitable combination of logic gate circuits, a programmable gate array (PGA), a field programmable gate array (FPGA), etc.

[0104] Embodiment 3, in this embodiment, in order to verify the beneficial effects of the present invention, scientific demonstration is carried out through economic benefit calculation and simulation experiments, and the following is the electric drive system fault test process.

[0105] 1) According to Figure 1 Correctly connect the motor controller, drive motor and electric drive system fault simulation device, and connect the electric drive system to the power supply and put it in a powered and working state;

[0106] 2) Through the control of the device host, enter the test parameters of level 1 fault or level 2 fault into the motor controller on the device button console. The test parameters of level 1 fault are: the number of faults within time t2 is less than i times and the motor speed is less than n.

[0107] 3) Select the working mode of the fault simulation device as needed. According to the test steps specified by the engineer, click the corresponding fault simulation type on the button operation console and click to confirm to realize the fault simulation;

[0108] 4) After time t2, the working status of the motor controller can be checked through the motor controller host computer to determine whether the motor controller performs fault management according to the established control method.

[0109] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. An electric drive fault simulation device, characterized in that: include: High voltage connecting wire, low voltage connecting wire, fault simulation circuit; The electric drive fault simulation device is connected to the low-voltage interface of the motor controller through a low-voltage connection line, and is connected to the three-phase high-voltage interface of the motor controller through a high-voltage connection line; The electric drive fault simulation device is connected to the low-voltage interface of the drive motor through a low-voltage connection line, and is connected to the three-phase high-voltage interface of the drive motor through a high-voltage connection line; The electric drive fault simulation device includes a plurality of fault simulation circuits, and two ends of each fault simulation circuit are respectively connected to the motor controller and the drive motor; The fault simulation circuit comprises a communication fault simulation circuit (100), a high-voltage interlock fault simulation circuit (200), an over-temperature fault simulation circuit (300), a resolver signal loss / abnormal fault simulation circuit (400), a phase current abnormality / hardware over-current fault simulation circuit (500), and an insulation failure fault simulation circuit (600); Each fault simulation circuit is respectively provided with a relay for controlling the on and off of the fault simulation circuit.

2. An electric drive fault simulation device as claimed in claim 1, characterized in that: The communication fault simulation circuit (100) comprises a first relay, a first connecting line, a second connecting line and a first resistor, one end of the first connecting line and the second connecting line are connected in series via the first relay and the first resistor, and the other ends of the first connecting line and the second connecting line are respectively connected to CANH and CANL of a vehicle CAN network via low-voltage cables.

3. The electric drive fault simulation device according to claim 1, characterized in that: The high-voltage interlock fault simulation circuit (200) comprises a second relay, a third connecting line, a fourth connecting line, two ends of the third connecting line are respectively connected to the low-voltage interface of the motor controller and the low-voltage interface of the motor, two ends of the fourth connecting line are respectively connected to the low-voltage interface of the motor controller and the low-voltage interface of the motor, and the second relay is arranged on the third connecting line or the fourth connecting line.

4. The electric drive fault simulation device according to claim 1, characterized in that: The over-temperature fault simulation circuit (300) comprises a third relay, a fifth connecting line, a sixth connecting line and a second resistor, wherein two ends of the fifth connecting line are respectively connected to a low-voltage interface of a motor controller and a low-voltage interface of a motor, and two ends of the sixth connecting line are respectively connected to a low-voltage interface of a motor controller and a low-voltage interface of a motor, and the third relay and the second resistor are arranged in series between the fifth connecting line and the sixth connecting line.

5. The electric drive fault simulation device according to claim 1, characterized in that: The resolver signal loss / abnormal fault simulation circuit (400) comprises a fourth relay, a fifth relay, a third resistor, a first excitation connection line, a second excitation connection line, a first sine connection line, a second sine connection line, a first cosine connection line and a second cosine connection line, wherein two ends of the first excitation connection line, the second excitation connection line, the first sine connection line, the second sine connection line, the first cosine connection line and the second cosine connection line are respectively connected to a low-voltage interface of a motor controller and a low-voltage interface of a motor, the fourth relay is arranged on any one of the first sine connection line, the second sine connection line, the first cosine connection line and the second cosine connection line, and the fifth relay is connected in series with the third resistor and then arranged in parallel with the fourth relay on any one of the first sine connection line, the second sine connection line, the first cosine connection line and the second cosine connection line.

6. The electric drive fault simulation device according to claim 1, characterized in that: The phase current anomaly / hardware overcurrent fault simulation circuit (500) comprises a sixth relay, a first high-voltage phase line, a second high-voltage phase line, a third high-voltage phase line and a fourth resistor, wherein two ends of the first high-voltage phase line are respectively connected to a high-voltage interface of a motor controller and a high-voltage interface of a motor, two ends of the second high-voltage phase line are respectively connected to a high-voltage interface of a motor controller and a high-voltage interface of a motor, and two ends of the third high-voltage phase line are respectively connected to a high-voltage interface of a motor controller and a high-voltage interface of a motor, and the sixth relay and the fourth resistor are connected in series and connected between any two high-voltage phase lines.

7. The electric drive fault simulation device according to claim 1, characterized in that: The insulation failure fault simulation circuit (600) comprises a seventh relay, a fifth resistor, a fourth high-voltage phase line, a fifth high-voltage phase line, a sixth high-voltage phase line and a vehicle body ground, wherein two ends of the fourth high-voltage phase line are respectively connected to a high-voltage interface of a motor controller and a high-voltage interface of a motor, two ends of the fifth high-voltage phase line are respectively connected to a high-voltage interface of a motor controller and a high-voltage interface of a motor, two ends of the sixth high-voltage phase line are respectively connected to a high-voltage interface of a motor controller and a high-voltage interface of a motor, and the seventh relay and the fifth resistor are arranged in series between any one of the high-voltage phase lines and the vehicle body ground.

8. An electric drive fault simulation method using an electric drive fault simulation device as claimed in any one of claims 1 to 7, characterized in that: include: Select different fault simulation modes; The fault simulation mode includes a single fault simulation mode and a multiple fault simulation mode; Based on different fault simulation modes, different control measures are taken for the relays of each fault simulation circuit.

9. The electric drive fault simulation method according to claim 8, characterized in that: The taking of different control measures for the relays of each fault simulation circuit based on different fault simulation modes includes, in the single fault simulation mode: Determine a fault type to be simulated, and control the relay of the fault simulation circuit corresponding to the fault type to close; When another fault type that needs to be simulated is determined, the relay of the fault simulation circuit that is currently turned on is controlled to be disconnected, and then the relay of the fault simulation circuit corresponding to the other fault type that needs to be simulated is controlled to be closed.

10. The electric drive fault simulation method according to claim 9, characterized in that: The taking of different control measures for the relays of the fault simulation circuits based on different fault simulation modes includes: in the multi-fault simulation mode: determining a plurality of fault types that need to be simulated, and controlling the closure of the relays of the fault simulation circuits corresponding to the plurality of fault types.

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